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A good friend of mine acually used this very method back in the early '80s to form big honkin' fender flares on his '67 Mustang. Home depot spray foam, then 'glassed over the top. Turned out VERY strong, but maybe he over did it just a little as it was his first try at it. Placed well in some local car shows as well.
This is acually a plausible method.
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